Fractionator feed tank pressure control

ABSTRACT

In a fractionation process in which at least two fractional distillation columns are cascaded in series, the vapor from the overhead accumulator associated with the first fractional distillation column in the series is provided to a feed tank for the second fractional distillation column in the series. The flow of the vapor from the overhead accumulator associated with the first fractional distillation column in the series is controlled by means of a control valve. An interactive control system is utilized to maintain the pressure in the overhead accumulator associated with the first fractional distillation column within safe operating limits, maintain the control valve at a substantially fully open position so as to minimize the pressure drop across the control valve controlling the flow of vapor from the overhead accumulator associated with the first fractional distillation column, and maintain the pressure in the feed tank to the second fractional distillation column at a desired value.

This application is a division of application Ser. No. 069,154, filedAug. 23, 1979, now U.S. Pat. No. 4,239,517.

This invention relates to control of a fractionation process. In anotheraspect this invention relates to method and apparatus for maintainingdesired valve positions and desired accumulator pressures in a multiplestage fractionation process.

In many processes it is desirable to preprocess the feed prior tointroduction of the components of the feed into the production process.An example of this is in the refining operation for the production ofethylene by cracking ethane and propane. The operation of the crackingprocess may be substantially optimized by separately cracking pureethane under optimized conditions and by separately cracking purepropane under optimized propane cracking conditions. Because the ethaneand propane are mixed in the feed to the ethylene process, it isnecessary to preprocess the feed to substantially split the ethane fromthe propane. Normally, this split is not complete with some propanebeing charged to the ethane cracking units and some ethane being chargedto the propane cracking unts. However, the preprocessing of the feedprovides a substantial improvement in the yield of the ethylene process.

The splitting of the feed may be carried out in a single stagefractional distillation or in a multiple stage fractional distillation.Where the splitting of the feed is carried out in a multiple stagefractional distillation process, a partial split will typically beobtained in a first fractional distillation column and a more completesplit will be obtained in a second fractional distillation column.Depending on the particular process, either the overhead or the bottomsfrom the first fractional distillation column will be supplied as a feedto the second fractional distillation column.

Where multiple fractional distillation columns are cascaded in series,it is essential that valve positions controlling the flow between thetwo fractional distillation columns be maintained so as to reducepressure drop across the control valves. It is further necessary tomaintain the pressure in the overhead accumulator associated with thefirst fractional distillation column within safe operating limits. It isalso desirable to maintain the pressure in the feed drum for the secondfractional distillation column at a level which will enable at least aportion of the vapors from the feed drum to be supplied directly to theprocess rather than being supplied to the second fractional distillationcolumn. It is thus an object of this invention to provide method andapparatus for maintaining desired valve positions and desiredaccumulator pressures in a multiple stage fractional distillationprocess.

In accordance with the present invention, method and apparatus isprovided whereby a feed which is to be split is supplied to a firstfractional distillation column. The overhead product from the overheadaccumulator associated with the first fractional distillation column isprovided to a feed tank for a second fractional distillation column. Theliquid from the feed tank for the second fractional distillation columnis supplied to the second fractional distillation column. This liquid issplit with the overhead product being supplied directly to the processin which the feed is to be used and the bottoms product also beingsupplied directly to the process. The overhead product from the firstfractional distillation column will be essentially the same as theoverhead product from the second fractional distillation column.However, there will be a higher concentration of the principal componentof the bottoms product in the overhead product from the first fractionaldistillation column than in the overhead product from the secondfractional distillation column.

The vapor portion of the feed in the feed tank for the second fractionaldistillation column is supplied directly to the process. This vaporportion will typically be mixed with the overhead product from thefractional distillation column. The vapor portion from the feed tank ofthe second fractional distillation column may also be utilized as a fuelgas and may be flared if required to maintain desired operatingpressures in the multiple stage fractional distillation process.

A control valve is utilized to control the flow of the overhead productfrom the first fractional distillation column to the feed tank for thesecond fractional distillation column. It is desirable that the controlvalve be held substantially fully open to minimize pressure drop acrossthe control valve. An interactive control system is utilized tomanipulate the pressure in the feed tank for the second fractionaldistillation column in such a manner that the control valve must be heldsubstantially fully open to maintain a desired operating pressure in theoverhead accumulator associated with the first fractional distillationcolumn. In this manner, a desired pressure is maintained in the overheadaccumulator associated with the first fractional distillation column andin the feed tank for the second fractional distillation column whilemaintaining the control valve position substantially fully open.

Other objects and advantages of the invention will be apparent from theforegoing brief description of the invention and the appended claims aswell as from the detailed description of the drawings which is adiagrammatic illustration of a two-stage fractional distillation processtogether with the valve position and pressure control system of thepresent invention.

The present invention is described in terms of an ethylene manufacturingprocess in which a feed consisting essentially of ethane and propane ispreprocessed prior to introduction into the cracking furnaces of theethylene manufacturing process. Ethane gas containing a small amount ofpropane is cracked in an ethane cracking furnace under optimal ethanecracking conditions. A propane gas containing a small portion of ethaneis cracked in a propane cracking furnace under optimum propane crackingconditions. Even though the invention is described in terms of specificprocess for the manufacture of ethylene, the applicability of theinvention described herein extends to other processes where it isdesirable to control the pressure in the accumulators and the valvepositions in a multiple stage fractional distillation process.

The invention is described in terms of a control system in whichspecific desired pressures are utilized to describe the preferredembodiment of the present invention. The invention is obviouslyapplicable to other operating pressures and is applicable to differentvalve positions if desired.

A specific control configuration is set forth in FIG. 1 for the sake ofillustration. However, the invention extends to different types ofcontrol system configurations which accomplish the purpose of theinvention. Lines designated as signal lines in the drawings arepneumatic in this preferred embodiment. However, the invention is alsoapplicable to electrical, mechanical, hydraulic or other signal meansfor transmitting information. In almost all control systems somecombination of these types of signals will be used. However, use of anyother type of signal transmission, compatible with the process andequipment in use, is within the scope of the invention.

The controllers shown may utilize the various modes of control such asproportional, proportional-integral, proportional-derivative, orproportional-integral-derivative. In this preferred embodiment,proportional-integral controllers are utilized but any controllercapable of accepting two input signals and producing a scaled outputsignal, representative of a comparison of the two input signals, iswithin the scope of the invention. The operation isproportional-integral controllers is well known in the art. The outputcontrol signal of a proportional-integral controller may be representedas

    S=K.sub.1 E+K.sub.2 ∫Edt

where

S=output control signals;

E=difference between two input signals; and

K₁ and K₂ =constants.

The scaling of an output signal by a controller is well known in controlsystems art. Essentially, the output of a controller may be scaled torepresent any desired factor or variable. An example of this is where adesired pressure and an actual pressure is compared by a controller. Theoutput could be a signal representative of a desired change in the flowrate of some gas necessary to make the desired and actual pressuresequal. On the other hand, the same output signal could be scaled torepresent a percentage or could be scaled to represent a temperaturechange required to make the desired and actual pressures equal. If thecontroller output can range from 3 lbs. to 15 lbs, which is typical,then the output signal could be scaled so that an output signal having avoltage level of 9 lbs. corresponds to 50 percent, some specified flowrate, or some specified temperature.

The various transducing means used to measure parameters whichcharacterize the process and the various signals generated thereby maytake a variety of forms or formats. For example, the control elements ofthe system can be implemented using electrical, analog, digitalelectronic, pneumatic, hydraulic, mechanical or other types of equipmentor combinations of one or more such equipment types. While the presentlypreferred embodiment of the invention preferably utilizes a combinationof pneumatic control elements and pneumatic signal handling andtranslation apparatus, the apparatus and method of the invention can beimplemented using a variety of specific equipment available to andunderstood by those skilled in the process control art. Likewise, theformat of the various signals can be modified substantially in order toaccommodate signal format requirements of a particular installation,safety factors, the physical characteristics of the measuring or controlinstruments and other similar factors. For example, a pressuremeasurement signal produced by a pressure measuring device could exhibita generally proportional relationship to the square of the actualpressure or a proportional relationship to the actual pressure. Inaddition, all signals could be translated into a "suppressed zero" orother similar format in order to provide a "live zero" and prevent anequipment failure from being erroneously interpreted as a low (or high)measurement or control signal. Regardless of the signal format or theexact relationship of the signal to the parameter which it represents,each signal representative of a measured process parameter orrepresentative of a desired process value will bear a relationship tothe measured parameter or desired value which permits designation of aspecific measured or desired value by a specific signal value. A signalwhich is representative of a process mesasurement or desired processvalue is therefore one from which the information regarding the measuredor desired value can be readily retrieved regardless of the exactmathematical relationship between the signal units and the measured ordesired process units.

Referring now to the drawing, a feed consisting essentially of ethaneand propane is provided through conduit means 11 to the fractionaldistillation column 12. A bottoms product which will consist essentiallyof propane and heavier components is withdrawn from a lower portion ofthe fractional distillation column 12 and is provided through conduitmeans 14 to another processing area. An overhead vapor stream which willconsist essentially of ethane and propane is withdrawn from an upperportion of the fractional distillation column 12 through conduit means16. The overhead vapor stream from the fractional distillation column 12is provided from the fractional distillation column 12 to the heatexchanger 17. A cooling fluid is provided to the heat exchanger 17through conduit means 18. The partially condensed fluid stream from theheat exchanger 17 is provided through conduit means 19 the overheadaccumulator 21. The portion of the fluid stream flowing through conduitmeans 19 which remains in vapor form is withdrawn from the overheadaccumulator 21 through conduit means 22 and is provided to the heatexchanger 23. The liquid portion of the fluid stream flowing throughconduit means 19 is withdrawn from the accumulator 21 and is providedthrough conduit means 25 as an external reflux to the fractionaldistillation column means 12.

The heat exchanger 23 is provided with a cooling fluid through conduitmeans 27. The partially condensed fluid stream from the heat exchanger23 is provided through conduit means 29 to the feed tank 31. The liquidportion of the fluid stream flowing through conduit means 29 is providedthrough conduit means 33 to the fractional distillation column 34. Thevapor portion of the fluid stream flowing through conduit means 29 isprovided through conduit means 34 and 36 to the ethane cracking furnacesassociated with the ethylene manufacturing process. The portion of thefluid flowing through conduit means 29 which remains in vapor form isalso provided through conduit means 34 and 37 as a fuel to the ethylenemanufacturing process and is provided through conduit means 34 and 38 toa flare.

A bottoms product is withdrawn from the fractional distillation column34 through conduit means 41. The bottoms product from the fractionaldistillation column means 34 will consist essentially of propane andwill be provided to the propane cracking furnaces associated with theethylene manufacturing process. An overhead vapor stream which willconsist essentially of ethane is withdrawn from the fractionaldistillation column means 34 through conduit means 43. The overheadvapor steam from the fractional distillation column means 34 is providedthrough conduit means 43 to the heat exchanger 45. The heat exchanger 45is provided with a cooling fluid through conduit means 46. The partiallycondensed fluid stream from the heat exchanger 45 is provided throughconduit means 48 to the overhead accumulator 49. The liquid portion ofthe at least partially condensed fluid stream flowing through conduitmeans 48 is provided through conduit means 51 as an external reflux forthe fractional distillation column means 34. The vapor portion of thefluid stream flowing through conduit means 48 is provided throughconduit means 53 and conduit means 36 to the ethane cracking furnacesassociated with the ethylene manufacturing process. The vapor portion ofthe at least partially condensed fluid stream flowing through conduitmeans 48 may also be provided to the feed tank 31 through conduit means53 and conduit means 56.

An interactive control system is utilized to manipulate the pressure inthe overhead accumulator 21, manipulate the pressure in the feed tank 31and to manipulate the valve position of the control valve 59 which isoperably located in conduit means 22. The pressure transducer 61, incombination with a pressure measuring device which is operably locatedin conduit means 22, provides an output signal 62 which isrepresentative of the pressure of the vapor flowing through conduitmeans 22. Signal 62 is provided as a first input to the pressurecontroller 63. The pressure controller 63 is also provided with a setpoint signal 64 which is representative of the desired operatingpressure for the overhead accumulator 21. In the preferred embodiment ofthe present invention the set point signal 64 is equal to 356 lbs.

In response to signals 62 and 64, the pressure controller 63 provides anoutput signal 65 which is responsive to the difference between signals62 and 64. Signal 65 is provided from the pressure controller 63 as aninput to the valve position indicating controller 66 and as a controlsignal to the pneumatic control valve 59. The pneumatic control valve 59is manipulated in response to signal 65 to thereby vary the flow rate ofthe vapor flowing through conduit means 22 so as to maintain a desiredoperating pressure in the overhead accumulator 21.

The valve position indicating controller 66 is also provided with a setpoint signal 71 which is representative of the desired position of thepneumatic control valve 59. In the preferred embodiment of the presentinvention, the set point signal 71 is representative of a value whichwill hold the pneumatic control valve 59 approximately 95 percent open.Responsive to signals 65 and 71, the valve position indicatingcontroller 66 provides an output signal 73 which is responsive to thedifference between signals 65 and 71. The output signal 73 from thevalve position indicating controller 66 is provided as an input to thehigh limit 74. The high limit 74 is also provided with a high limitsignal 75 which is representative of the highest desired pressure in thefeed tank 31 which is preferably 335 lbs. The lower of signals 73 and 75is provided as signal 76 to the pressure controller 78. Signal 76 may beconsidered a set point for the pressure controller 78.

The pressure transducer 83, in combination with a pressure measuringdevice which is operatively located in the feed tank 31, provides anoutput signal 84 which is representative of the pressure in the feedtank 31. Signal 84 is provided as an input to the pressure controller78, the pressure controller 86, the pressure controller 87 and thepressure controller 88.

In response to signals 76 and 84, the pressure controller 78 provides anoutput signal 89 which is responsive to the difference between signals76 and 84. Signal 89 is provided as a control signal to the pneumaticcontrol valve 91 which is operably located in conduit means 34. Thepneumatic control valve 91 is manipulated in response to signal 89 so asto maintain a desired pressure in the feed tank 31.

The pressure controller 87 is provided with a set point signal 93 whichis preferably representative of 340 lbs. If the pressure in the feedtank 31 should exceed 340 lbs., then the output signal 94 from thepressure controller 87 which is responsive to the difference betweensignals 84 and 93 is utilized to manipulate the pneumatic control valve96, which is operably located in conduit means 37, so as to reduce thepressure in the feed tank 31.

The pressure controller 88 is provided with a set point signal 98 whichis representative of 350 lbs. If the pressure in the feed tank 31 shouldexceed 350 lbs., the output signal 99 from the pressure controller 88 isutilized to manipulate the pneumatic control valve 101 which is operablylocated in conduit means 38, so as to reduce the pressure in the feedtank 31. Signal 99 is responsive to the difference between signals 98and 84 and is utilized to manipulate the control valve 101 only if thepressure in the feed tank exceeds 350 lbs.

The pressure controller 86 is provided with a set point signal 103 whichis preferably representative of 315 lbs. In response to signals 84 and103, the pressure controller 86 provides an output signal 104 which isresponsive to the difference between signals 84 and 103. Signal 104 isprovided as a control signal to the pneumatic control valve 106 which isoperably located in conduit means 56. If the pressure in the feed tank31 should fall below 315 lbs., the pneumatic control valve 106 is openedin response to signal 104 so as to allow ethane from the overheadaccumulator 49 to flow into the feed tank 31. In this manner, thepressure in the feed tank 31 may be raised if desired.

It is desirable to maintain the pressure in the feed tank 31 between 315lbs. and 335 lbs. so that at least a portion of the vapor in the feedtank 31 can be provided through conduit means 34 and 36 to the ethanecracking furnaces associated with the ethylene manufacturing process. Afeed tank pressure in the range of about 315 lbs. to about 335 lbs. alsoenables the pneumatic control valve 59 to be in a substantially fullyopen position while still maintaining a desired operating pressure inthe overhead accumulator 21. Maintaining the pneumatic control valve 59in a substantially fully open position reduces the pressure drop acrossthe pneumatic control valve 59 which is desirable.

The liquid level in the feed tank 31 is maintained at a desired level bythe level controller 111. The output signal 112 from the levelcontroller 111 is provided as a control signal to the pneumatic controlvalve 113 which is operably located in the conduit means 33. Thepneumatic control valve 113 is manipulated in response to signal 112 soas to maintain a flow rate of liquid through the conduit means 33 whichwill maintain a desired liquid level in the feed tank 31. The levelcontroller 111 and the pneumatic control valve 113 do not interact withthe valve position and pressure control system previously described.

The following example is presented to further illustrate the presentinvention.

Assume that pneumatic control valve 59 is fully closed when signal 65 isequal to 3 lbs. and is fully open when signal 65 is equal to 15 lbs.This is a typical operating condition. Further assume that when signal65 is equal to 14.5 lbs. the pneumatic control valve 59 will beapproximately 95% open. Thus, signal 71 would be representative of 14.5lbs.

Assume that the pressure in the overhead accumulator 21 is equal to 356lbs. which is the value of the set point signal 64. Further assume thatthe output from the pressure controller 63 is equal to 10 lbs. and thepneumatic control valve 59 is thus not 95 percent open as is desiredalthough the pressure in the overhead accumulator 21 is equal to the setpoint pressure. The difference between the set point signal 71 andsignal 65 will thus be 4.5 lbs. Assume, that this 4.5 is scaled in sucha manner that signal 73 is equal to 320 lbs. Signal 73 is thus providedas the set point signal to the pressure controller 78. The pressurecontroller 78 will act to close the pneumatic control valve 91 so as toincrease the pressure in the feed tank 31. This increase in the pressurein the feed tank 31 will be reflected back to the overhead accumulator21 and the pressure in the overhead accumulator 21 will start to rise.When this occurs, signal 62 will be greater than the set point signal 64and it will be assumed that the output signal 65 from the pressurecontroller 63 will assume a value equal to 11 lbs. which will open thepneumatic control valve 59 more fully and reduce the pressure in theoverhead accumulator 21 back to the set point value. It is noted thateven though the pressure in the overhead accumulator 21 is reduced backto the set point value the value of signal 65 will remain at 11 lbs. andwill not return to 10 lbs. as is well known to one skilled in the use ofcontrollers.

Signal 65, which is now representative of 11 lbs., is again compared tosignal 71 and the difference is now 3.5 lbs. Assume that this 3.5 lbs.signal is scaled so that signal 73 is representative of 328.33 lbs.Signal 73 will be provided as the set point signal to the pressurecontroller 78. The pressure controller 78 will again act to close thepneumatic control valve 91 so as to raise the pressure in the feed tank31 to 328.33 lbs. This increased pressure in the feed tank 31 will bereflected back to the overhead accumulator 21 and the pressure in theoverhead accumulator 21 will again begin to rise. Again signal 62 willbe greater than signal 64 and it will be assumed that signal 65 willincrease to 12 lbs. which will further open the pneumatic control valve59. The difference between signal 65 and signal 71 is now 2.5 lbs. whichis scaled in such a manner that signal 73 is representative of 331.66lbs. This process is continued until the pressure in the feed tank 31has been raised to approximately 335 lbs. When the pressure in theoverhead accumulator 21 is equal to approximately 356 lbs. and thepressure in the feed tank 31 is equal to approximately 335 lbs., thepneumatic control valve 59 will be approximately 95 percent open. Inthis manner, the interactive valve position and pressure control systemmaintains a desired operating pressure in the overhead accumulator 21and in the feed tank 31 while maintaining a desired valve position forthe pneumatic control valve 59.

If the pressure in the feed tank 31 should rise above 340 lbs., thepressure controller 87 acts to try to reduce the pressure by opening thepneumatic control valve 96. If the pressure in the feed tank 31 shouldrise above 350 lbs., the pneumatic control valve 88 acts to reduce thepressure by opening the pneumatic control valve 101. If the pressure inthe feed tank 31 should fall below 315 lbs., the pneumatic control valve86 acts to increase the pressure in the feed tank 31 by opening thepneumatic control valve 106.

The invention has been described in terms of a preferred embodiment asillustrated in FIG. 1. Specific components used in the practice of theinvention as illustrated in FIG. 1 such as pressure transducers 61 and83, pneumatic control valves 59, 91, 96, 101, 106 and 113; pressurecontrollers 63, 88, 87, 78 and 86; level controller 111; and valveposition indicating controller 66 are each well known, commerciallyavailable control components such as are described at length in Perry'sChemical Engineer's Handbook, 4th Edition, Chapter 22, McGraw-Hill. Thehigh limit 74 is preferably a B04719 Limit Select, manufactured byApplied Automation, Inc., Bartlesville, Oklahoma.

For reasons of brevity, conventional auxiliary fractionation equipmentsuch as pumps, heat exchangers, additional measurement-control devices,etc., have not been included in the above description as they play nopart in the explanation of the invention.

While the invention has been described in terms of the presentlypreferred embodiments, reasonable variations and modifications arepossible by those skilled in the art within the scope of the describedinvention and the appended claims.

That which is claimed is:
 1. A method for controlling a multi-stagefractional distillation process in which the overhead product from afirst fractional distillation column is supplied from a first overheadassumulator associated with said first fractional distillation columnthrough a first control valve to a feed tank for a second fractionaldistillation column comprising the steps of:establishing a first signalrepresentative of the pressure in said first accumulator; establishing asecond signal representative of the desired pressure in said firstaccumulator; using a computing means to establish responsive to saidfirst signal and said second signal, a third siganl responsive to thedifference between said first signal and said second signal;manipulating said first control valve in response to said third signalto thereby maintain a desired pressure in said first accumulator;establishing a fourth signal representative of a desired valve positionfor said first control valve; using a computing means to establishresponsive to said third signal and said fourth signal, a fifth signalresponsive to the difference between said third signal and said fourthsignal; establishing a sixth signal representative of the pressure insaid feed tank; using a computing means to establish responsive to saidfifth signal and said sixth signal, a seventh signal responsive to thedifference between said fifth signal and said sixth signal; andmanipulating the pressure in said feed tank in response to said seventhsignal, the pressure in said first overhead accumulator and the pressurein said feed tank being manipulated so as to maintain a desired valveposition for said first control valve.
 2. A method in accordance withclaim 1 wherein said step of manipulating the pressure in said feed tankin response to said seventh signal comprises supplying the vapor in saidfeed tank through a second control valve as a feed to a process, saidsecond control valve being manipulated in response to said seventhsignal.
 3. A method in accordance with claim 2 comprising the additionalsteps of supplying at least a portion of the vapor in said feed tankthrough a third control valve means as a fuel to a process.
 4. A methodin accordance with claim 3 comprising the additional stepof:establishing an eighth signal representative of a pressure which isgreater than the highest pressure obtainable by said fifth signal; usinga computing means to establish responsive to said eighth signal and saidsixth signal, a ninth signal responsive to the difference between saideighth signal and said sixth signal; and manipulating said third controlvalve in response to said ninth signal if the pressure in said feed tankexceeds the pressure represented by said eighth signal.
 5. A method inaccordance with claim 4 comprising the additional step of flaring atleast a portion of the vapor in said feed tank through a fourth controlvalve.
 6. A method in accordance with claim 5 comprising the additionalsteps of:establishing a tenth signal representative of a pressure whichis greater than the pressure represented by said eighth signal; using acomputing means to establish responsive to said tenth signal and saidsixth signal, an eleventh signal responsive to the difference betweensaid tenth signal and said sixth signal; and manipulating said fourthcontrol valve in response to said eleventh signal if the pressure insaid feed tank exceeds the pressure represented by said tenth signal. 7.A method in accordance with claim 6 comprising the additional steps ofsupplying at least a portion of the overhead product from said secondfractional distillation column through a fifth control valve to saidfeed tank.
 8. A method in accordance with claim 7 comprising theadditional steps of:establishing a twelfth signal representative of thelowest desired operating pressure of said feed tank; using a computingmeans to establish responsive to said sixth and twelfth signal, athirteenth signal responsive to the difference between said sixth signaland said twelfth signal; and manipulating said fifth control valve inresponse to said thirteenth signal so as to open said fifth controlvalve if the pressure in said feed tank falls below the valuerepresented by said twelfth signal to thereby increase the pressure insaid feed tank.